Title:
Adjusting manufacturing process control parameter using updated process threshold derived from uncontrollable error
Document Type and Number:
United States Patent 7349753

Abstract:
A method, system and medium are provided for enabling improved feedback and feedforward control. An error, or deviation from target result, is observed during manufacture of semi conductor chips. The error within standard deviation is caused by two components: a white noise component and a signal component (such as systematic errors). The white noise component is random noise and therefore is relatively non-controllable. The systematic error, in contrast, may be controlled by changing the control parameters. A ratio between the two components is calculated autoregressively. Based on the ratio and using the observed or measured error, the actual value of the error caused by the signal component is calculated utilizing an autoregressive stochastic sequence. The actual value of the error is then used in determining when and how to change the control parameters. The autoregressive stochastic sequence addresses the issue of real-time control of the effects of run-to-run deviations, and provides a mechanism that can extract white noise from the statistical process variance in real time. This results in an ability to provide tighter control of feedback and feedforward variations.
Inventors:
Paik, Young J. (Campbell, CA, US)
Application Number:
11/102438
Publication Date:
03/25/2008
Filing Date:
04/08/2005
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Assignee:
Applied Materials, Inc. (Santa Clara, CA, US)
Primary Class:
International Classes:
G06F19/00; G05B13/02
Field of Search:
700/45, 700/33, 700/44, 700/108-110, 700/31, 702/84, 700/51, 700/34
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Primary Examiner:
Jarrett, Ryan A.
Attorney, Agent or Firm:
Wilmer Cutler Pickering Hale & Dorr
Parent Case Data:

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 10/855,711, filed May 28, 2004 now U.S. Pat. No. 6,961,626, which is incorporated herein its entirety by reference. This application is related to co-pending U.S. patent application Ser. No. 10/856,016, filed May 28, 2004, entitled Improved Process Control By Distinguishing a White Noise Component of a Process Variance which is incorporated herein its entirety by reference.

Claims:
What is claimed is:

1. A computer-implemented method for controlling a manufacturing process, comprising the steps of: (a) inputting a model for the manufacturing process and obtaining a manufacturing recipe based on the model, wherein the model predicts at least one value for a product characteristic of at least one product processed by the manufacturing process; (b) receiving at least one observed value for the product characteristic of the at least one product and determining a variance between the at least one observed value and the at least one predicted value; (c) determining a value for uncontrollable error from the variance; (d) using the value for uncontrollable error to update a process threshold; and (e) adjusting at least one control parameter of the manufacturing process using the updated process threshold, wherein the manufacturing process includes at least one device on which the at least one product is processed, the at least one device being affected by the at least one control parameter.

2. The method of claim 1, wherein the variance is determined from the at least one observed value observed for N previously processed products.

3. The method of claim 2, wherein N is in the range of 5 to 100.

4. The method of claim 2, wherein N is in the range of 10 to 40.

5. The method of claim 1, further comprising the step of: using the value for uncontrollable error to update the at least one control parameter.

6. The method of claim 5, wherein the value for uncontrollable error is used as a weighing factor to adjust an estimated gain in the updating of the at least one control parameter.

7. The method of claim 1, wherein the value fo